Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Counter Hold Tool (T10355) for vehicles with a S-Tronic transmission
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Engine Support Bridge (10-222 A)
• Shop Crane (VAS 6100)
• Drip Tray for VAS 6100 (VAS 6208)
Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance +/- 15%.
Tightening specifications, refer to => [ Subframe Overview ] Subframe Overview.
Additional Tightening Specifications
Manual Transmission to Engine Fastener
Procedure
• Replace any bolts that were tightened with an additional turn.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• The hose connections and charge air system hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts Catalog.
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• When installing, bring all cable ties back to the same positions.
- Check if the alignment sleeves for centering the engine/transmission are in the cylinder block and insert them if they are not.
- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
- The following preparations must be made before connecting the engine and transmission:
- Make sure the intermediate plate is engaged on the sealing flange and slide onto the guide sleeves - arrows -.
- Insert the (T40169) into the transmission housing and clutch module from underneath as illustrated.
• The (T40169) must engage in the semi-circular opening - 1 - and in the inspection hole - 2 -.
• The inspection hole is only in one location on the circumference so rotate the clutch module as needed.
- Insert the (T40170) in the transmission housing from below and clamp it onto the flange shaft - 1 -.
• The following step is necessary only if there is a drive plate with mounting pins - 2 - installed.
- Align the drive plate to the clutch module so the mounting pins - 2 - (if equipped) on the drive plate can engage in the large holes - 1 - on the clutch module.
The clutch will not function properly if it is installed incorrectly.
• If the drive plate mounting bolts - 2 - are not in the clutch module hole - 1 -, the clutch will not function properly.
• The bolt - 2 - attaches the starter to the transmission and has an additional spacer sleeve - arrow -.
• Pay attention to the spacer sleeve when removing or installing the engine - arrow -. The spacer sleeve must be inserted between the starter and the transmission.
- Attach the transmission to the engine and tighten the bolts - 7 through 11 -. Tightening specifications.
- Release the tension on the (10-222 A) spindles.
- Lower the (VAS 6100) and mount the engine and transmission onto the engine mount.
- Install the left and right engine mount bolts - 1 -.
- Remove the (VAS 6100) and (2024 A).
- Install and tighten the engine/transmission bolts - 1 through 6 -.
• Ignore - A -.
- Remove the (T40170) and the (T40169).
• The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.
- Press the clutch module - 2 - slightly against the drive plate - 3 - using a pry bar - 1 - in direction of - arrow -.
Tightening Sequence - Clutch Module to the Drive Plate
- Install the first bolt - arrow - hand-tight.
- Turn the crankshaft another 120° in the direction of engine rotation and install the second bolt hand-tight.
- Turn the crankshaft again 120° in the direction of engine rotation.
- Tighten the third bolt to the tightening specification.
- Tighten the remaining bolts to the tightening specification.
Install in reverse order of removal.
- Install starter.
- Install the catalytic converter. Refer to => [ Catalytic Converter ] Catalytic Converter.
- Install the front exhaust pipe/front muffler. Refer to => [ Front Exhaust Pipe and Front Muffler ] Front Exhaust Pipe and Front Muffler.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Aligning ] Exhaust System, Aligning.
- Install Air Conditioning (A/C) compressor.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Electrical connectors and wiring routing.
- Install the Engine Control Module (ECM).
- Install the electrical wires, terminal 30 wire junction 2 (TV22) and the engine compartment E-box cover.
- Install the tower brace.
- Install the washer fluid reservoir filler tube.
- Follow measures after connecting battery.
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
- Install the air filter housing.
- Install the lock carrier in service position. Procedures
Check the oil level.
- Fill with coolant => [ Filling ] Service and Repair.
• Do not use drained coolant in the following situations:
• If the cylinder head or cylinder block was replaced.
• If the coolant is contaminated.
- Install the noise insulation and the wheel housing liners.